Industrial producers usually battle with capability, labor pressure, and consistency.
At Korea Filter Engineering, guide palletizing of 10–20 kg (22-44 lb) industrial filter bins was limiting output, growing ergonomic danger, and slowing deliveries.
After deploying the Robotiq PE20 with a UR20, the corporate achieved:
- 30% manufacturing improve
- 50% discount in employee fatigue
- Close to 50% discount in injury-related absences
- Zero office incidents since set up
- ROI anticipated inside 2 years
This case research reveals how collaborative robotic palletizing improves productiveness whereas defending staff in heavy-load manufacturing environments.
Firm overview: Industrial filter manufacturing in South Korea
Based in 1996 and primarily based in Gimpo, Korea Filter Engineering manufactures industrial filters utilized in electrical discharge machining (EDM).
- Trade: Industrial filter manufacturing
- Staff: 15
- Each day palletizing load (earlier than automation): ~4 tons
- Field weight: 10–20 kg
With a lean workforce and rising demand, guide palletizing grew to become a manufacturing bottleneck.
The problem: Guide palletizing of heavy bins
Earlier than automation, staff manually lifted and stacked roughly 4 tons of product per day.
Key points included:
1. Ergonomic danger and employee fatigue
- Repetitive lifting of 20 kg bins
- Again, shoulder, and muscle pressure
- Ageing workforce growing damage danger
- Fatigue affecting morale and consistency
2. Productiveness limitations
- Each day output capped at 200 bins
- Delays brought on by bodily pressure and absenteeism
- Problem sustaining constant throughput
3. Failed options
Earlier lifting aids have been examined however operations repeatedly reverted to totally guide palletizing on account of complexity or inefficiency.
The corporate wanted an answer that was:
- Compact
- Secure
- Straightforward to function
- Secure for human-robot collaboration
- Fast to deploy
The answer: Robotiq Lean Palletizing
In early 2025, Korea Filter Engineering chosen the Robotiq PE20 palletizer built-in with the UR20 collaborative robotic.
Why this palletizing system?
- Handles bins as much as 20 kg
- Helps as much as 20 SKUs
- Most pallet top: 2130 mm (84 in)
- Compact footprint for space-constrained services
- Works alongside staff with out in depth security fencing
- Intuitive interface requiring minimal coaching
Quick deployment timeline
- Early 2025: Analysis
- March 2025: Citation
- Might 2025: Set up and launch
Minimal structure modifications have been required. The system built-in seamlessly with the prevailing conveyor.
Operators have been capable of be taught and run the system inside minutes, decreasing dependency on specialised robotics experience.
Outcomes: Measurable features in productiveness and security
1. 30% manufacturing improve
- Output elevated from 200 to 250 bins per day
- Greater throughput with out growing headcount
- Improved supply reliability
2. Improved employee well being and security
- Harm-related absences almost halved
- Employee fatigue lowered by greater than 50%
- Zero office incidents since set up
Younger-Hun Yoo, Assistant Supervisor in Manufacturing, shared:
“After utilizing the robotic, our our bodies are more healthy, and we really feel much less drained—lower than half in comparison with earlier than. We now have extra vitality left for our households after work.”
3. Workforce optimization
- One full-time worker reassigned to higher-value duties
- Much less bodily pressure, extra operational focus
- Stronger workforce morale
4. Sturdy monetary case
- Anticipated return on funding inside 2 years
- Decreased oblique prices associated to damage and absenteeism
- Elevated capability with out increasing facility area
Why collaborative robotic palletizing works in heavy manufacturing
This mission demonstrates key benefits of cobot palletizing techniques:
Protects staff from repetitive heavy lifting
Eradicating 4 tons of day by day guide lifting dramatically reduces ergonomic danger.
Will increase output with out increasing workforce
Automation dietary supplements labor as an alternative of changing it.
Scales with product variability
The PE20 handles as much as 20 SKUs, supporting numerous product strains.
Matches in space-constrained services
Compact design makes it viable for small and mid-sized producers.
Allows quick ROI
Measurable productiveness and security enhancements speed up payback.
Woo-Seok Kim, Director of Enterprise, defined the choice:
“We checked many robotic techniques, however the PE20 was probably the most steady. Defending our staff is an important factor, and the PE20 permits us to do this. That’s the reason it’s definitely worth the funding.”
Key takeaways for producers contemplating automation
In case your operation includes:
- Guide palletizing of heavy bins
- Repetitive lifting inflicting fatigue or accidents
- Labor shortages or growing older workforce challenges
- Restricted flooring area
- Productiveness plateaus on account of bodily constraints
Collaborative palletizing automation might ship speedy, measurable influence.
Korea Filter Engineering’s transformation proves that producers don’t have to decide on between:
- Productiveness and security
- Progress and workforce wellbeing
- Automation and operational stability
With the fitting palletizing resolution, you’ll be able to obtain all three.
Is Lean Palletizing the fitting match on your manufacturing line?
Use Robotiq’s Palletizing Match Software to shortly assess whether or not cobot palletizing is sensible on your operation and what a sensible deployment might appear to be on your facility. You may even get customized estimates for ROI and payback durations and a 3D simulation of what Lean Palletizing might appear to be in your manufacturing facility flooring.
